Residential construction method and apparatus

ABSTRACT

Home residential construction based on the use of panels made of metal cladding with expanded polystyrene therebebetween. The metal cladding is preferably 26-gauge galvanized steel and the thickness of the panels is approximately six inches. Such a panel is strong enough to serve as a roof panel, a wall panel or a floor panel and will be dimensionally similar to the roofs, walls, and floors of existing homes. A pitched roof is formed of roof panels, supported by a bar joist at the peak. Walls are formed of wall panels joined using trays for their bottom ends and caps for their top ends and sides. A residence constructed using the present materials and methods is stronger than conventional “brick and stick” homes and can be constructed more quickly and cheaply, and is less expensive to heat and cool.

Generally, the present invention relates to residential construction. In particular, it relates to a material for use as wall material and methods for using that material.

Historically, homes, some apartments and smaller offices are built on the jobsite using bricks and lumber, plus other materials such as shingles and insulation panels. These materials can be used to construct an endless variety of residences, from simple tract homes to elaborate custom-built homes.

Although great strides have been made in pre-assembling some components, such as roof trusses and windows and doors, in factories where they can be made more quickly and cheaply, still most of residential construction is made at the jobsite, laying one brick and nailing one “2 by 4” at a time. As a result, a significant component of residential construction cost is for labor.

Another disadvantage of residential construction that is related to the fact that homes are largely built on site is that the quality of construction is uneven. When foundations are made of bricks individually laid and walls are made of individual studs nailed together, there inevitably will be flaws. Most of these flaws are minor, but even minor ones, when sufficiently numerous, add up to a significantly higher heating and cooling bill.

Thus there remains a need for better ways to build residences of better quality and lower cost of construction as well as heating and cooling.

SUMMARY OF THE INVENTION

According to its major aspects and briefly recited, the present invention is a method and apparatus for constructing residences. The term “residences” will be used to refer to one and two-story structures with pitched roofs, including individual homes, duplexes, small office buildings and small apartment buildings, but not warehouses, large office buildings and other commercial buildings of more than two stories.

In particular, the present invention is characterized by the use of panels made of metal cladding with expanded polystyrene between. The panels are adapted to meet the strength requirements and dimensional requirements of residential specifications. For example, the metal cladding is preferably 26-gauge galvanized steel and the thickness of the panels is approximately six inches. Such a panel will be strong enough to serve as a roof panel, a wall panel or a floor panel and will be dimensionally similar to the roofs, walls, and floors of existing homes so that further modifications of construction techniques and materials (i.e., window units) will be unnecessary. When these panels are supported and joined as described herein, with their bottom ends set in trays and their top ends capped, they form strong, weather-tight, energy-efficient floors, walls, and roofs and result in homes that appear to be much like conventional “brick and stick” homes but can be constructed more quickly and cheaply and are less expensive to heat and cool. They are also quieter.

A feature of the present invention is the use of insulated panels. These panels are known in warehouse construction as “freezer panels.” Some types of freezer panels, namely those with urethane between the cladding, are unsuitable for residential construction because of the gases given off by the urethane. However, those that are made of expanded polystyrene (EPS, known more commonly under the trademark STYROFOAM), preferably those made of EPS foamed with air, are unknown in residential construction. These panels, in addition to being sufficiently strong enough for making warehouse walls, are also energy efficient for refrigeration purposes. When applied to residential construction, their energy efficiency rating is much higher than conventional materials provide.

Another feature of the present invention is the use of a bar joist to support the roof panels at the peak of the roof. A bar joist avoids the need for roof trusses. Bar joists are commonly found in supporting flat surfaces such as flat roofs and floors. They are not found as supports for pitched roofs. Roof trusses work well in traditional homes but make attic space largely unusable other than for storage of boxes because the existence of the trusses require those walking around in an attic to keep their heads low to avoid injury. By eliminating trusses, there is more usable space just under the roof. Furthermore, bar joists, in combination with the structural strength of the panels, provides a sufficiently strong roof.

Another feature of the present invention is the use of trays and caps in combination with the panels to provide a rigid structure for a roof, a wall or a floor.

A particular feature of the present invention is the use of EPS several inches thick. EPS has considerable thermal efficiency and makes the present method and materials especially attractive in very cold and very warm climates, particularly those that are subject to strong winds or heavy snows.

Other features and their advantages will be apparent to those skilled in the art of lamp design from a careful reading of a Detailed Description Of Preferred Embodiment accompanied by the following drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 illustrates a typical residence that can be made using the present construction methods or prior art methods;

FIG. 2 illustrates a foundation and wall joint, according to a preferred embodiment of the present method;

FIG. 3 illustrates a support for a wall, according to a preferred embodiment of the present invention;

FIG. 4 illustrates a mid-floor support for a floor, according to a preferred embodiment of the present invention;

FIG. 5 illustrates a detailed portion of the roof joint at the roof peak, made according to a preferred embodiment of the present invention;

FIG. 6 illustrates a detailed portion of the roof and wall joint, made according to a preferred embodiment of the present invention; and

FIG. 7 illustrates a partially cut away view of the end of a roof, made according to a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is a construction method and apparatus for building residences. An important aspect of the present invention is the use of pre-fabricated panels made of a cladding, preferably a metal cladding and most preferably of a galvanized steel cladding with expanded polystyrene (EPS) therebetween. Also, the EPS is preferably made using air to expand it rather than some other gas. The EPS is preferably at least approximately four and most preferably approximately six inches thick or even thicker when thickness is important. The term “approximately” is used in the sense of a “two-by-four” is approximately two inches by four inches. If the cladding is galvanized steel, it is preferably 26-gauge, galvanized steel. The cladding may be pre-painted or primed prior to use.

These panels are used as roof panels and also preferably as wall and floor panels. Although these panels in a form referred to as “freezer panels” are known in construction of warehouses for cold storage, freezer panels in residential construction using air-expanded polystyrene is unknown.

In addition to the use of panels for the roof, walls and floor, there are particular techniques disclosed herein for joining the panels, particularly in the foundation and the pitched roof of the residence. These techniques will now be described

Referring now to FIG. 1, there is shown a typical residential home 10 including a roof 12 with shingles 14, walls 16 with windows 18, a porch 20 and a foundation 22. Home 10 could be made with prior art materials and techniques or with the present materials and techniques. However, the exterior and interior finish will look the same. To those living in a home made of the present materials constructed with the present techniques, there would be few differences in appearance and in operation, but these would be important differences. One of these differences would be the energy efficiency when home 10 is made according to the present invention. A monthly energy bill for heating and cooling the present home would be much smaller, perhaps one-half to one-third the amount of the bill for the same home made with conventional techniques and materials. Use of the present materials and techniques also results in a quieter home in that noise outside the home is attenuated to a greater degree by the walls.

Another difference apparent to those living in home 10 when made with the present materials and techniques as opposed to prior art materials and techniques, is the absence of trusses in the attic, making the attic more usable for storage or living space. Less apparent to those who live in home 10, constructed with present materials and techniques, is the strength of home 10 against strong winds.

Referring now to FIGS. 2-4, there are illustrated details of foundation 22 of home 10, according to a preferred embodiment of the present invention. As in a conventional home, a concrete footer (see FIG. 3 and 4) is poured and a foundation is constructed on a footer. In the present invention, a foundation 32 (also laid on a footer 30, now shown in FIG. 2) may consist of a block wall 34 with a brick facing 36, capped with a wood board 38, as illustrated in FIG. 2. Alternatively, and for support interior to foundation 32, steel pipes 44 embedded in footer 30 may be used to hold a steel I-beam 42, as illustrated in FIGS. 3 and 4. In FIG. 3, a foundation board 40 is supported by an I-beam 42 on a steel pipe 44 using a steel bracket 46. In FIG. 4, a foundation board 48 is secured to an I-beam 50, supported on a steel pipe 52 for a floor support interior to foundation 32.

Foundation boards 38, 48, are preferably two by eight or two by ten boards. Steel pipes 44, 52 are preferably four-inch steel pipes. Bracket 46 is preferably galvanized sheet steel formed so that it can be attached to the side of I-beam 42 and to foundation board 40 extending laterally inward, thus providing support for floor panels 56. Floor panels 56 can be placed in adjacent relationship, running from exterior wall to exterior wall, secured together to define a floor for home 10.

A metal tray 60, dimensioned to received wall panels 62 is attached to foundation boards 38, 48. Wall panels 62 are secured to tray 60 using long screws. The tops of wall panels 62 are joined with a cap 64 (see FIG. 6) using long screws. Trays 60 and caps 64 are preferably made of galvanized channel steel. Holes may be formed in wall panels 62 to accommodate standard windows and doorframes as desired. Windows and doors are framed and set wall panels 62, as in conventional construction. Caps 64 are preferably angled at the pitch of roof (see FIG. 6). Floor panels 56 and wall panel 62 have cladding 66 on both sides with EPS 68 therebetween.

As shown in FIGS. 5, 6, and 7, the formation of a pitched roof 70 requires support at the peak 72 and at the eves 74. Roof panels 76 are strong enough if properly supported at peak 72 and eves 74 to support the weight of, for example, workers on roof 70 installing shingles. Roof 70 will be finished on its upper side in a conventional manner using plywood boards 78 secured to roof panels 76, then covered with felt 80 and then shingles 82 as shown in FIGS. 5, 6, and 7. Roof panel 76 like floor panel 56 have cladding 84 of galvanized steel on both sides and EPS 86 therebetween.

At peak 72, roof panels 76 are brought together and sealed with liquid polystyrene 94 as a sealer and supported at peak 72 with a support system 96 that runs the length of roof 70. Support system 96 includes a bar joist 98 secured to the underside of roof panels 76, at peak 72 by a series of pitch forms 100 secured to roof panels 76, either directly or using peak support boards 102 running the length of the joint at peak 72. Preferably roof panels 76 have long screws 104 driven entirely through plywood boards 78, roof panels 76, peak support boards 102 and into pitch forms 100. Bar joist 98 is secured to pitch members using screws.

Bar joist 98 is supported at the tops of opposing walls using a flanged end bracket 110 using screws. End bracket 110 may be a rectangular box only on the ends of bar joist 98 or may run the length of bar joist enclosing it. The interior of bracket 110 is preferably backfilled with foam insulation 112 to form an enclosed, insulated box running the length of roof peak.

At eves 74, roof panel 76 has a facie cap 120 and a soffet piece 122 joined to wall panel 62 with an “F” trim piece 124. Roof panel 76 is secured to wall panel 62 with a long screw, preferably through plywood 78, roof panel 76, and cap 64, and has an end cap 126 on the ends of roof panels 76 not terminated at a peak 72 or eve 74, as shown in FIG. 7.

All EPS is air-expanded rather than using another gas or rather than using urethane. EPS is strongly preferred as a core for floor, wall and roof panels 56, 62, and 76. It does not give off gases over time; it remains stable from the standpoint of its insulating properties; it has a high “R” value that ranges up to 94; it is an excellent vapor barrier; it is easy to work with at the job site; and it is low in cost.

It is intended that the scope of the present invention include all modifications that incorporate its principal design features, and that the scope and limitations of the present invention are to be determined by the scope of the appended claims and their equivalents. It also should be understood, therefore, that the inventive concepts herein described are interchangeable and/or they can be used together in still other permutations of the present invention, and that other modifications and substitutions will be apparent to those skilled in the art of lamp manufacture from the foregoing description of the preferred embodiments without departing from the spirit or scope of the present invention. 

1. A method for constructing a residence, said method comprising the steps of: forming a foundation for a residence; placing trays on said foundation; setting wall panels into said trays, said wall panels each being made of cladding with expanded polystyrene therebetween; placing caps onto said wall panels; fastening said trays and said caps to said wall panels; and installing a pitched roof onto said panels.
 2. The method as recited in claim 1, wherein said pitched roof further comprises roof panels made of cladding with expanded polystyrene therebetween.
 3. The method as recited in claim 1, further comprising the step of installing a floor on said foundation, said floor further comprising floor panels made of cladding with expanded polystyrene therebetween.
 4. The method as recited in claim 1, wherein said cladding is galvanized steel.
 5. The method as recited in claim 1, further comprising the step of positioning a bar joist between said wall panels near said cap to support said roof.
 6. The method as recited in claim 1, further comprising the step of providing I-beams interior to said foundation and installing a floor on said I-Beams and said foundation, said floor comprising floor panels made of cladding with expanded polystyrene therebetween.
 7. The method as recited in claim 2, further comprising the step of sealing adjacent roof panels using liquid polystyrene.
 8. A residence, comprising: a foundation; trays attached to said foundation; walls made of wall panels having a top and an opposing bottom, said bottom of said wall panels being inserted into and fastened to said trays, said wall panels made of cladding with expanded polystyrene therebetween; caps fastened to said tops of said wall panels; means carried by said walls for supporting a roof; a pitched roof supported by said roof supporting means; and a floor carried by and fastened to said foundation.
 9. The residence as recited in claim 8, wherein said pitched roof further comprises roof panels made of cladding with expanded polystyrene therebetween.
 10. The residence as recited in claim 9, wherein said roof supporting means is a bar joist.
 11. The residence as recited in claim 9, wherein said cladding of said wall panels and said roof panels is galvanized steel.
 12. The residence as recited in claim 9, wherein said polystyrene is expanded with air.
 13. The residence as recited in claim 9, further comprising: plural supports; and an I-beam attached to said supports for supporting said floor.
 14. The residence as recited in claim 13, wherein said floor further comprises floor panels attached to said I-Beam and said foundation, and wherein said floor panels are made of cladding and expanded polystyrene therebetween
 15. A residence, comprising: a foundation; a floor carried by said foundation; walls carried by said foundation; and a pitched roof carried by said walls, said pitched roof made of plural roof panels, each roof panel of said plural roof panels made of cladding with expanded polystyrene therebetween.
 16. The residence as recited in claim 15, further comprising a bar joist carried by said walls, and wherein said roof is supported by said bar joist.
 17. The residence as recited in claim 16, wherein said roof has a peak, and wherein said bar joist supports said peak of said pitched roof.
 18. The residence as recited in claim 17, wherein said roof panels are joined at said peak using liquid polystyrene.
 19. The residence as recited in claim 15, wherein said walls and said floor further comprise wall panels and floor panels, respectively, said wall panels and said floor panels being made of cladding with expanded polystyrene therebetween.
 20. The residence as recited in claim 19, wherein said polystyrene of said roof panels, said wall panels and said floor panels are made of polystyrene expanded with air. 